Floor construction



FLOOR CONSTRUCTION Filed July 14, 1942 4 Sheets-Sheet 1 vl/sawmed @na/erHopfen/LL @JMW Aug. 31, 1943. R. HoPEwELL FLOOR CONSTRUCTION Filed July14, 1942 4 Sheets-Sheet 2 i l WQ@ nvm. nvm.

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FLOOR CONSTRUCTION Filed July 14, 1942 4 Sheets-Sheet 3 liIG. 4.

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FLOOR CONSTRUCTION Filed July 14 1942 4 Sheets-Sheet 4 /Nz/eA/Toe.foesg-r J/op: WELL, 3f

Patented A'ug. 31., 1943 UNITED STATES PATENT OFFICE Application July14, 1942, Serial No. 450,899 In Great Britain March 19, 1941 (Cl.'Z2-66) Claims.

This invention relates to the construction of iioors and ceilingscomposed of concrete or like slabs and aims at simplifying theconstruction of such fioors and ceilings.

The invention consists in a method of and means for constructing iioorsand ceilings, the means provided comprising a set of I-section beams, aset of cradles adapted to stand upon wall portions of a structure and tohave interlocking engagement with said beams and to support same inraised positions above said wall portions of a structure, a set ofconcrete or like slabs having edges shaped to engage into the channelsof the beams, and means for holding the beams in parallel and spacedrelation, the method of construction consisting in setting up thecradles, beams and slabs, the beams being held in spaced relation by themeans provided for this purpose, encasing the cradles and cradle-engagedends of the beams in a concrete mass which binds to the wall to form anupper portion thereof, feeding concrete mix between each beam and theslabs situated on the respective Sides thereof, and removing the spacingmeans when the concrete has set.

In a preferred form of the invention, there are provided a set ofI-section beams each of which has an under-cut longitudinal ribprojecting from the outer face of its head and foot, a set of cradlesadapted to stand upon wall portions of a structure end to engage saidbeams by their bottom ribs and support said beams in raised positionslabove said wall portions of a structure, a set of concrete or like slabshaving edges shaped to engage into the channels of the beams, and meansfor engaging the top ribs of the beams for holding said beams inparallel and spaced relation to one another.

The method of construction according to such preferred form of theinvention consists in placing a cradle on the top of a wall, placinganother cradle on the top of an opposite wall, engaging the respectiveends of a beam with said cradles, erecting another beam in the samemanner in parallel and spaced relation to said rst beam, locking thebeams in such spaced relation by engaging the spacing means with theupper projecting ribs of the beams, sliding a set of slabs along thespace between said beams after engaging the edges of the slabs with therespective beams, encasing the cradles and cradle-engaged ends of thebeams in a concrete mass which binds to the wall to form an upperportion thereof, feeding concrete mix between each beam and the slabspositioned on the respective sides thereof,

and removing the said spacing means when the concrete has set.

A concrete filling is inserted between the adjacent edges ofadjoiningblocks and the interposed beam so as to form a solid structure,and if the beams are provided with bottom ribs as well as the top ribs,then these bottom ribs can serve as keys for holding concrete llinginserted into cavities which exist between adjacent blocks at theirundersides, thus forming a level continuation of the underfaces of theslabs as required for a ceiling. l

The cradles serve the purpose of raising the beams to such an extent aswill allow the slabs to be slid into position along the erected beamswithout obstruction by the tops of the walls.

In order that the invention may be readily understood, reference isdirected to the accompanying drawings, wherein:

Figure 1 is a plan view of a partially completed building showing thebeams provided by the invention erected and positioned ready forreceiving the concrete slabs and showing the positions at which sectionsthrough a completed floor and which are shown in other views, are taken,

Figure 2 is a sectional elevation through an assembly provided by theinvention and showing steps carried out in constructing the floor,

Figures 3 to 6 inclusive are sections on lines III-III, V-IV, V-V, andVI--VI respectively on Figure l, through the completed floor,

Figure is a fragmentary plan view of a beam showing the manner ofarranging the spacing means in staggered relation,

Figure 8 is a perspective view showing one end of a beam and one form ofcradle for engaging same, and

Figure 9 is a perspective View of another form of cradle.

Referring to the drawings, there is provided a set of I-section beams orgirders IG, each of said beams having an undercut longitudinal rib I Iprojecting from the outer face of its head flange'IZ and a similar ribI3 projecting from the outer face of its foot iiange I4.

For the purpose of supporting said beams on partially completed wallsthere are provided cradles of two different patterns for use indifferent locations as hereinafter described. The shoe of one patternshown in Figure 8 comprises a body portion l5 having parallel-walledcavities I6 separated by a cross rib il, said body portion beingprovided at its base with projecting anges I8 constituting feet. Thebeam to be engaged with this form of cradle has a notch le formed in itsbottom rib I3 (Figure 8) and in placing the beam in position same islowered vertically so that its rib i3 enters the cavities lo, the crossrib Il of the cradle entering the notch 9; this ensures endwise locationof the beam. The cradle of the alternative form (Figure 9) has a bodyportion 2i) in which is formed a longitudinally extending dovetailgroove 2l terminating short oi one end of said body portion, the latterbeing provided at its base with projecting flanges 22 constituting feet.A beam is engaged with this form of cradle by sliding said beam endwiseinto position so that its bottom rib i3 passes along the groove 2 Thedepth of the cavities it in. the one form of cradle and or the groove 2lin. the other form of cradle is such that the footl flange il of thebeam is able to seat upon the upper facie of the cradle.

Hollow concrete blocks 23 are provided to form l the main body of thefloor or ceiling. Each of said blocks is shaped at each end to provide aledge 24 adapted to enter the groove in one side of a beam Hl, thedisposition of said ledge being such that when same beds on to the footM of the beam, a lower part of the block depends down below the level ofsaid'foot i4 of the beam as clearly shown in Figure 2. The sides 25 ofsaid depending part slope outwardly, i. e. diverge from one another inthe downward direction. The upper corners of the block are obliquely cutaway as at 26 to leave a space between the upper portion of the blockand the head iiange l2 of the adjacent beam. The upper and the underfaceof the block` are formed with dovetail grooves 2l,

23 to serve as concrete mix ioated on to the top and underface of theblock.

Means is provided for engaging the beams and holding same in spacedrelation, during the construction of the oor, said means comprisingmetal rods 29 (Figure 2) having screw-threaded ends, and pairs ofclamping blocks le each formed with a recess adapted to engage over oneIside of an upper rib Il of a beam lil and shapedv to conform to saidrib, the said blocks constituting opposed jaws which are adapted to gripbetween them the beam rib Il by tightening up nuts 3| which bear againstthe outer faces of said blocks 3Q.

In Figure l, which serves merely as a key to the other igures of thedrawings, the spaces A and B between wallsof the building form passagesand the space C is one provided for a stairway. Reference D indicatespartially completed walls of the building which have been built up allto the same height, and reference E indicates supplementary beams whichare bedded into the partially completed walls so as to flush therewith,said supplementary beams providing support for groups F and G of themain beams l0 las hereinafter explained.

Dealing now with the manner of constructing a floor which is to providealso a ceiling for the rooms beneath, cradles 20 of the form shown inFigure 9 are laid upon those walls D of the building which are requiredto support the ends of the beams l0, said cradles being placed inequidistant spaced-apart relationship. No such support need be providedat points intermediate in the length of a beam l0 where same passesover` parting walls. rhusV each of the beams which extends right acrossthe building will be supported at its two ends only, by cradles mountedon the partially completed outside walls, one of these being shown onthe extreme left of Figure l. To effect this mounting of the beams, thecradles 2D are slid on to the ends of the beams l0 so that the grooves2| of said cradles receive the bottom ribs I3 of the beams. The endwalls 32 of the cradles constitute end stops adapted to abut the ends ofthe beams.

To support those ends of the groups F and G of beams which overlie thesuspended supplementary beams E, cradles I5 of the form shown in Figure8 are laid upon the said supplementary beams E, and the main beams l!!which are to seat upon said cradles, are simply lowered into place sothat the bottom rib portions I3 of the beam engage into the cradlecavities i6, the cross-rib Il of each cradle passing into the notch I9vof the associated beam l0.

The spacing means is then applied to the beams Il! to locate and holdthe same in their required spaced-apart. positions (Figure 2). This iscarriedv out. by bringing the two co-acting blocks 3i) provided on oneofthe rods 2S, in positions to engage the top rib l of one beam l0 andclamping up said blocks by manipulating the nuts 3l. Whilst holding thenext beam at the correct distance, the blocks 3,0 provided on the otherend of said rod 2 9 `are slid up against the respective ysides of thetop rib il o1.` saidsecond beam and are clamped thereto by tightening upthe associated nuts 3 Each rod 29 serves to connect two adjacent beamsonly, and consecutive rods 29 yare disposedin staggered relation asshown in Figure 7.

Having erected the beams lll. as above eX- plained, the spaces betweensame are lled by sliding a number ofblocks. 23 alongeach of such spacesafter engagingl the ledges dei said blocks with the channels` of thebeams. By. reason of they cradles raising the beamswell above thepartially completed walls D, clearance is provided to allowthe dependingparts of the blocks to pass over said Walls.k The blocks are arranged tomutually contactso that they wholly occupy the space between the beams,and their ledges 24 vrest on the foot iianges i4 vof the beams as isclearly shown in, FigurefZ.

Blanking tiles 33 which are-cut :away to fit over the beams l0, `are.now placed one adjacent to each of the cradles 20 as shown in` Figure4, said tilev being positioned so that a face thereof is flush with theinner surface of the wall D. A concretemass is now built on to the wallD, this mass beingA retained between an outer brick 34,

, which is simultaneously laid in position, and the bl'anking tile 33.Said concretemass encases and binds on to the cradles and cradle-engagedends of thev beams,l thereby securely bonding same. Bricks are now laidin the spaces between the beams lll,v tocontinue the building up of thewan D.

The cradles l5 mounted ,onA the supplementary beamsE alsoV are 'bondedinplaceby encasing 4same and the adjacent endscfbeams i0 in a concretemass builtI ontosaid beams E, and preferably,'befor e carryingoutthisnoperation a reinforcement 35 which may consist of expanded metalfabric, is warrangedtonupstand behind the end of the adjacentbeam Ill."kThe reinforcement plate 35 may be secured to any desired further similarreinforcement 35.

A illing of concrete mix 3'1"' (Figure 2) isnow insertedbetweenthebevams it! and the blocks 23 so as to lill the Ispaceswhich exist dueto the sloped-ofi` faces 2B of the blocks. When this filling sets itfirmly bonds the blocks to the beams. This enables the spacing meanscomprising the rods 2.9 and clamping blocks 3S to be removed. Suchspacing means is replaced by reinforcement rods 33, the hooked ends ofwhich are engaged over the top ribs ll of the beams (Figure 3). Aconcrete mass 38 is now built on to the blocks so as to embed thereinforcement rods 33 and form a floor surface. This concrete mass isextended to provide a body of any desired form about the reinforcementsand 36 (Figure 5), for instance, one which forms a handrail-receivingchannel 4i), and which has a vertical face 4l flush with a face of theassociated supplementary beam E. As shown in Figure 4, said concretemass 38 may be carried over the cradles 20 to unite with the previouslylaid concrete whch bonds and cradles to the wall, the arrangement beingsuch that same provides a surface level with adjoining brickwork toallow the building of the upper part of wall D to progress.

In order to form a ceiling surface a concrete mix 42 is floated on tothe underfaces of the blocks 23 (Figure 3). This facing keys into thegrooves 28 of the blocks and additionally it is forced into the cavitiesof dovetail form due to the slope of the side faces 25 of the dependingportions of the blocks and this provides a further key for said facing42. Also the said facing will key on to the bottom ribs I3. Thiscombination will ensure secure bonding of the said facing 42.

In regard to the space H (Figure 1) overlying a wall running parallel tothe beams ID, it is preferred to mount an assembly of small blocks whichtogether occupy the full width of the space. That .is to say, there willbe provided a centre block bedding directly upon the said wall and apair of side blocks each having one ledge similar to the ledge 24 of theprincipal blocks adapted to fit in th'e channel side of the adjacentbeam, each of said side blocks having a depending portion which reachesto and beds upon the wall. Thus there is no space between the wall andthe blocks requiring to be filled in. Cement filling is run into spacesexisting between the centre block and side blocks so as to bond theparts of the assembly.

Referring now to Figures l and 6, it will be appreciated that one sideof the beam J would be exposed unless some provision were made forencasing same. Accordingly the beam used for this position has apre-cast mass of concrete 44; that is to say such concrete mass is caston to the beam over any suitable reinforcing and retaining means 45 suchas expanded metal fabric, this operation being carried out in the makingof the completed beam before same is taken up for use, the concretefacing 44 being applied, of course, only at those positions where thebeam would be otherwise exposed.

It is to be understood that if the structure is not required to providea floor but only provides a ceiling, then there is no need to apply theupper concrete facing 39.

I claim:

1. In a building construction, the combination with the walls of thebuilding, beam cradles provided with sockets mounted on the tops of saidwalls, beams of substantially I-shaped cross section each having ribsprojecting from the top and bottom sides thereof, said ribs at thebottoms of the beams having their ends fitting in the sockets of thecradles, pre-formed fireproof slabs having laterally projecting ledgesadapted to rest on the lower flanges of the beams and to span the spacetherebetween, the tops of said slabs lying substantially in the plane ofthe top flanges of the beams and the bottoms of said slabs lying in aplane below the bottom flanges of the beam, and a settable plasticmaterial covering the top and bottom of said beams and slabs to bond thesame together and completely encase the same.

2. In a building construction, the combination, with the Walls of thebuilding, beam cradles provided with sockets mounted on the tops of saidwalls, beams of substantially I-shaped cross section each havinglongitudinally disposed top and bottom ribs, said bottom ribs at theends of the beams fitting in the sockets of the cradles, preformedreproof units having ledges projecting from opposite sides thereof andprovided at their upper and lower surfaces with a plurality ofdove-tailed key channels, said ledges adapted to be supported on theupper sides of the lower flanges of the beams, and the tops of saidunits being disposed substantially in the plane of the top flanges ofthe beams while the lower faces thereof are disposed below the lowerfaces of the bottom flanges of the beam, and a settable plastic materialencasing the tops and bottoms of the beams and said units and keying inthe channels of said units.

3. In a construction for floors, ceilings and the like, the combinationwith the walls of the building, of a beam cradle having a cavitypositioned on the supporting surface of a building wall, a beam ofsubstantially I-shaped cross section and having a bottom longitudinallydisposed rib, the said rib fitting into the cavity of the cradle,precast units disposed between and supported on the lower flanges of theI-beams, and a settable plastic covering and enveloping the beams andsaid units.

4. In a construction for floors, ceilings, or the like, the combinationwith the wall of a building, of a beam cradle positioned on the wall andhaving a socket and a recess separated by an intervening wall, a beamhaving a longitudinal rib depending from its bottom face, the said ribbeing provided near its end with a notch to receive said interveningwall of the cradle whereby the portion of said rib nearest the end willfit in said socket and the portion of the rib inwardly of the notch willnt into the said recess of the cradle, a pre-cast unit supported by thebeam, and a settable plastic covering for said beam and unit.

5. In a construction for floors, ceilings or the like, the combinationwith the walls of the building, of a cradle positioned on one of thewalls and including a body having a recess opening at one end and closedat the other, a beam including top and bottom flanges and having a ribdepending from the bottom flange, the portion of the rib near the end ofthe beam fitting in said recess when the bottom of the flange rests ontop of the cradle, a pre-cast unit supported by a. portion of the beam,and a settable plastic covering encasing the unit and beam.

ROBERT HOPEWELL.

